ESAB Railtrac B42V Instruction manual

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Railtrac™ B42V

Instruction manual

0463 465 101 GB 20201021

Valid for: 1634 xxxx

SAFETY

1.1 Meaning of symbols

1.2 Safety precautions

INTRODUCTION

TECHNICAL DATA

INSTALLATION

4.1 Connections

4.2 Assembly

4.3 Assembly instructions for the optional Orbital kit

OPERATION

5.1 Preheat

5.2 Remote control for digital wire feeder

5.3 Electronic – Carriage

5.4 Remote control

5.5 Installation of wire feeder

MAINTENANCE

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ORDERING SPARE PARTS ORDERING NUMBERS ACCESSORIES

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23 24 25

Rights reserved to alter specifications without notice.

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1 SAFETY

1.1 Meaning of symbols

As used throughout this manual: Means Attention! Be Alert!

DANGER! Means immediate hazards which, if not avoided, will result in immediate,

serious personal injury or loss of life.

WARNING! Means potential hazards which could result in personal injury or loss of life.

CAUTION! Means hazards which could result in minor personal injury.

WARNING!

Before use, read and understand the instruction manual and follow all labels, employer´s safety practices and Safety Data Sheets (SDSs).

NOTE!

For product operation instructions please refer to the supplied USB memory stick.

1.2 Safety precautions

Users of ESAB equipment have the ultimate responsibility for ensuring that anyone who works on or near the equipment observes all the relevant safety precautions. Safety precautions must meet the requirements that apply to this type of equipment. The following recommendations should be observed in addition to the standard regulations that apply to the workplace.

All work must be carried out by trained personnel well-acquainted with the operation of the equipment. Incorrect operation of the equipment may lead to hazardous situations which can result in injury to the operator and damage to the equipment.

1. Anyone who uses the equipment must be familiar with: ○ its operation ○ location of emergency stops ○ its function ○ relevant safety precautions ○ welding and cutting or other applicable operation of the equipment

2. The operator must ensure that: ○ no unauthorised person is stationed within the working area of the equipment

when it is started up

○ no-one is unprotected when the arc is struck or work is started with the

equipment

3. The workplace must: ○ be suitable for the purpose ○ be free from drafts

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1 SAFETY

4. Personal safety equipment: ○ Always wear recommended personal safety equipment, such as safety glasses,

flame-proof clothing, safety gloves

○ Do not wear loose-fitting items, such as scarves, bracelets, rings, etc., which

could become trapped or cause burns

5. General precautions: ○ Make sure the return cable is connected securely ○ Work on high voltage equipment may only be carried out by a qualified

electrician

○ Appropriate fire extinguishing equipment must be clearly marked and close at

hand

○ Lubrication and maintenance must not be carried out on the equipment during

operation

WARNING!

Arc welding and cutting can be injurious to yourself and others. Take precautions when welding and cutting.

ELECTRIC SHOCK - Can kill

• Install and ground the unit in accordance with instruction manual.

• Do not touch live electrical parts or electrodes with bare skin, wet gloves or wet clothing.

• Insulate yourself from work and ground.

• Ensure your working position is safe

ELECTRIC AND MAGNETIC FIELDS - Can be dangerous to health

• Welders having pacemakers should consult their physician before welding. EMF may interfere with some pacemakers.

• Exposure to EMF may have other health effects which are unknown.

• Welders should use the following procedures to minimize exposure to EMF:

○ Route the electrode and work cables together on the same side of

your body. Secure them with tape when possible. Do not place your body between the torch and work cables. Never coil the torch or work cable around your body. Keep welding power source and cables as far away from your body as possible.

○ Connect the work cable to the workpiece as close as possible to the

area being welded.

FUMES AND GASES - Can be dangerous to health

• Keep your head out of the fumes.

• Use ventilation, extraction at the arc, or both, to take fumes and gases away from your breathing zone and the general area.

ARC RAYS - Can injure eyes and burn skin

• Protect your eyes and body. Use the correct welding screen and filter lens and wear protective clothing.

• Protect bystanders with suitable screens or curtains.

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NOISE - Excessive noise can damage hearing

Protect your ears. Use earmuffs or other hearing protection.

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1 SAFETY

MOVING PARTS - Can cause injuries

• Keep all doors, panels and covers closed and securely in place. Have only qualified people remove covers for maintenance and troubleshooting as necessary. Reinstall panels or covers and close doors when service is finished and before starting engine.

• Stop engine before installing or connecting unit.

• Keep hands, hair, loose clothing and tools away from moving parts.

FIRE HAZARD

• Sparks (spatter) can cause fire. Make sure that there are no inflammable materials nearby.

• Do not use on closed containers.

MALFUNCTION - Call for expert assistance in the event of malfunction.

PROTECT YOURSELF AND OTHERS!

CAUTION!

This product is solely intended for arc welding.

WARNING!

Do not use the power source for thawing frozen pipes.

CAUTION!

Class A equipment is not intended for use in residential locations where the electrical power is provided by the public low-voltage supply system. There may be potential difficulties in ensuring electromagnetic compatibility of class A equipment in those locations, due to conducted as well as radiated disturbances.

NOTE! Dispose of electronic equipment at the recycling

facility!

In observance of European Directive 2012/19/EC on Waste Electrical and Electronic Equipment and its implementation in accordance with national law, electrical and/or electronic equipment that has reached the end of its life must be disposed of at a recycling facility.

As the person responsible for the equipment, it is your responsibility to obtain information on approved collection stations.

For further information contact the nearest ESAB dealer.

ESAB has an assortment of welding accessories and personal protection equipment for purchase. For ordering information contact your local ESAB dealer or visit us on our website.

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2 INTRODUCTION

Railtrac™ B42V is a system of components that can be configured to create the optimal solution for your mechanized welding application. To minimise problems associated with harsh environments, most mechanical parts are constructed in aluminium or stainless steel.

Railtrac™ B42V is designed for horizontal and vertical joints (up and down, when applicable).

With the optional Orbital kit the B42V can be used for orbital welding of pipes from 20" and up in horizontal and vertical joints with or without weaving.

Features Railtrac™ B42V

• 42VAC or battery driven with standard Makita® 18V system.

• High speed and low speed in one unit.

• Micro process controlled electronics package in a single onboard housing.

• Stepper motor both for drive and weaving function.

• Only one cable to the wire feeder (not needed if using the battery) and one cable to the remote control (if used) but can be run without any remote control.

• The unit can be programmed and run directly from the controls on the Railtrac™ machine if the remote control is lost-damaged or not preferred.

• Dual high-visibility screens for easy viewing in any orientation.

• The remote is programmable for weave patterns and travel speed and is capable of controlling voltage and wire feed speed in up to 5 standard programs.

• Intermittent welding

• IP44 environmental rating on both the Railtrac™ and the remote control.

• Choose between welding on left side or right side for remote to correspond to carriage movement.

• With the optional Orbital kit the B42V can be used for orbital welding of pipes from 20" and up in.

Direct connection to all new modern ESAB wire feeders

Railtrac™ B42V can be easily connected to most ESAB wire feeders with no major modification. Remote adapters have to be mounted in wire feeders (Aristo®Feed3004, Aristo®Feed4804, Origo™Feed304, Origo™Feed484 and Warrior™Feed304).

Five programs can easily be stored

As many as five different programs can be stored. Each program is individual and can be retrieved from the control on the main unit or the remote control.

Remote control of welding parameters and immediate program shift

Both welding current (wire-feed speed) and voltage can be adjusted (in %) during welding. Stepping up or down between the alternative motion programs is also easy, depending on welding position.

Resilient programming units with great potential

Straightforward, logically-designed programming units are used to set the values for five different programs. All speeds are calibrated in millimetre (mm), for the greatest possible precision and welding quality.

Remote control for the harshest environments

Using the robust and lightweight remote control that comes with the Railtrac™ B42V, the operator can access and control every function without lifting the welding visor. Individually shaped buttons for:

• Start and stop

• Shift program

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2 INTRODUCTION

• Travel or welding direction (cutting direction)

• Travel or welding speed (cutting speed)

• Weaving width

• Zero-line displacement

• Welding current (wire-feed speed)

• Welding voltage

Orbital kit

With the optional Orbital kit you can convert the B42V into a Pipe welder that can be used for orbital welding of pipes from 20" and up, in horizontal and vertical joints, with or without weaving.

Joint rail system for stiff or flexible rail applications

The extendable Railtrac™ combi-rail enables the same tractor to run on a flexible rail or the same rail stiffened with a stiffener bar. The stiffener-bar rail fits into the existing holes in the rail. This makes it possible to weld straight as well as curved surfaces (min 1600mm in diameter). The combi-rail is clean, without a rack for driving the tractor. If longer rails are needed it is easy to joining several rails.

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2 INTRODUCTION

1. Slide height adjustment 7. Locking wheel

2. Support wheel holder 8. Locking screw

3. Bracket for coarse adjustment in/out

9. Electronics

and height

4. Universal torch holder 10. Battery holder

5. Protection plate 11. Weaving movement

6. Drive wheel ×2 12. Weaving movement connection

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2 INTRODUCTION

Dimensions

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3 TECHNICAL DATA

Supply voltage 24 - 70 V DC

20 - 50 V AC

18 V battery (optional)

Power consumption max 50 W

Battery running time 3 - 4 h (5Ah)

Weight 8 kg (17.63 lb.)

Carriage measurements (L×W×H) 210 × 360 × 270 mm (8.26 × 14.17 × 10.62

in.)

Min bending diam. rail Ø 1600 mm (62.99 in.)

Max temp. magnet/vacuum att. 70°C / 90°C (158°F / 194°F )

Max pay load 10 kg (22.04 lb.)

Max pay load with battery 5 kg (11.02 lb.)

High adjustment slide +/- 45 mm (± 1.77 in.)

Speed carriage 0.4 - 25 mm/s (0.01 - 0.98 in./s)

Rapid speed carriage 30 mm/s (1.18 in./s)

Rapid speed battery 25 mm/s (0.98 in./s)

Welding length - auto return 10 - 9999mm. Tolerance±1 mm (0.39

-393.66 in.Tolerance±0.04 in.)

Weaving speed 10 - 50 mm/s (0.39 - 1.97 in./s)

Weaving pattern 3

Weaving width 0 - 30 mm (0 - 1.18 in.)

0-line adjustment ± 30 mm (± 1.18 in.)

Mechanical adj. in/out ± 40 mm (± 1.57 in.)

Tot. movement weaver 80 mm (3.15 in.)

Dwell time weaving 0.0 - 5.0 s

Programs 5

Remote control Wire Feed Speed and V

ESAB 0 - 10 V

(separate adj. on each program)

Safety Class DIN40050

Enclosure class IP44

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4 INSTALLATION

The installation must be carried out by a professional.

4.1 Connections

Information and drawings from ESAB.

4.2 Assembly

Follow these steps to assemble brackets, carriage, torch holder and for connection of the control box.

1. Assemble the magnet brackets on the aluminium rail.

Optional: Attach the stiffener bar.

1. Flip magnet 3. Flex rail

2. Assembly screws 4. Stiffener (optional)

2. Adjust the rail parallel to the joint.

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4 INSTALLATION

3. Put the carriage on the rail.

4. Tighten the locking screw (1).

5. Connect the remote control to the carriage and the control cable to ESAB wire feeder.

Use the battery when not using ESAB wire feeder.

6. Mount the torch and adjust for correct position (2).

7. Secure the rail from falling down by way of a wire or the like.

4.3 Assembly instructions for the optional Orbital kit

Orbital kit part no.: 0398 146 801

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4 INSTALLATION

1. Power off and disconnect cables.

2. Turn the drive wheel (1) into the position shown in the illsutration with a wrench (2).

1. Drive wheel 2. Wrench

3. Use the wrench to lock the drive wheels (3) as you loosen the two bolts (1) and

remove the disks (2) and the drive wheels (3).

1. Bolts 3. Drive wheels

2. Disks

4. Remove the four screws (1).

1. Screws

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4 INSTALLATION

5. Use the lift screw (1) to pull up the short drive wheel unit from motor axle (3).

1. Screw 3. Motor axle

2. Short drive wheel

6. Remove the short drive wheel unit (1) and the long drive wheel unit (3).

1. Short drive wheel unit 2. Long drive wheel unit

7. Replace the long drive wheel unit (2) and chain (1).

1. Chain 2. Long drive wheel unit

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4 INSTALLATION

8. Mount the short drive wheel unit (1) and the long drive wheel unit (2). Press the short

drive wheel unit carefully on the axle and drive in the four screws (3).

9. Mount the drive wheels (1) and the new disks (2).

1. Drive wheels 2. Disks

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5 OPERATION

General safety regulations for handling the equipment can be found in the "SAFETY" chapter of this manual. Read it through before you start using the equipment!

5.1 Preheat

The first menu in service is Preheat. Start delay carriage after start welding.

WFS = Wire Feed Speed

1. Press Stop for 6 seconds for access to service menu A.

2. Release Stop when the display shows Service Menu A . The electronics will stay in the service menu 5 seconds after last button press.

3. The default setting is 300 ms. Press + or - to adjust the setting.

5.2 Remote control for digital wire feeder

It is possible to adjust the maximum value on the remote control output (0-10 V) both for wire feed speed and volt. The maximum value is 0.5 V lower than Vin(10 V) due to the voltage

drop in the opto driver.

Set Wire Feed Speed (WFS)

1. Press Menu once. The display shows: DigF max WFS

2. Press + or - to adjust the setting. Scale value: 1 - 40 Higher value gives higher output.

Set Voltage (V)

1. Press Menu until DigF max V is shown in the display.

2. Press + or - to adjust. Scale value: 1 - 40 Higher value gives higher output.

General safety regulations for handling the equipment can be found in the "SAFETY" chapter of this manual. Read it through before you start using the equipment!

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5 OPERATION

5.3 Electronic – Carriage

One press: Start left without welding

1 Start left

Double press: Start left with welding

Press 2 seconds: Start with fast move left

One press after start: Speed carriage -

Before start: Selector for programming parameters. Blinking display indicates progamming modus. Adjust parameters with

2 Menu/Stop

the buttons + and -.

After start: Stop carriage and welding.

If function Length: Press for 3 seconds to set start position. Display shows 0.

One press: Start right without welding

Double press: Start right with welding

3 Start right

Press 2 seconds: Start with fast move right

One press after start: Speed carriage +

Menus

Program P1 to P5 Railtrac™ can store 5 different programs.

Speed Carriage 0.4 – 25 mm/s (0.01 - 0.98 in./s)

Speed weaving 10 – 50 mm/s (0.39 - 1.97 in./s)

Weaving width 0 – 30 mm (0 - 1.18 in.)

Pattern 3

Hold time out 0.0 – 5.0 s

Hold time in 0.0 – 5.0 s

WFS Wire Feed Speed 1 – 99% (Only for ESAB wire feeders)

Volt 1 – 99% (Only for ESAB wire feeders)

Length 10 – 10000 mm (0.39 - 393.70 in.) – Set welding length. At the end

the carriage make a return with rapid speed back to start pos. 0 mm (0 in.) = function off.

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5 OPERATION

Menu 10-12, new SW from serial no.: 1940xxxx

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5 OPERATION

Menu 5: Weaving pattern

5.4 Remote control

1 Shift

2 Stop

3 Weaving width - WFS-

4 One press: Start up

Volt +

Double press: Start up with arc

Press 2 seconds: Start with fast move up

One press after start: Speed +

5 0-line in

6 One press: start down

Volt -

Double press: Start down with arc

Press 2 seconds: Start with fast move down

One press after start: Speed -

7 Program - Menu -

8 Program + Menu +

9 0-line out

10 Weaving width + WFS+

5.5 Installation of wire feeder

The installation must be carried out by a professional.

Railtrac™B42V can be connected to one of the following wire feed units: Aristo®Feed3004, Aristo®Feed4804, Origo™Feed304, Origo™Feed484 and Warrior™Feed304.

For necessary adaptation between Railtrac™B42V and the used wire feed unit (including choice of control cable), see the "ACCESSORIES" appendix to this manual.

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5 OPERATION

Universal feeder connection

For the operation of Railtrac™B42V from other wire feeders (none ESAB), use transformer unit and control cable according to the "ACCESSORIES" appendix.

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6 MAINTENANCE

NOTE!

All warranty undertakings given by the supplier cease to apply if the customer attempts to rectify any faults on the machine during the warranty period.

Daily

• Check that all cables and plugs are intact.

• Clean the magnet, vacuum cups and air hoses and check for damage.

• Check that the rail is not damaged.

• Clean the carriage and the torch holder.

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7 ORDERING SPARE PARTS

CAUTION!

Repair and electrical work should be performed by an authorised ESAB service technician. Use only ESAB original spare and wear parts.

Railtrac B42V is designed and tested in accordance with the international and European standard EN 60974-10 Class A. On completion of service or repair work, it is the responsibility of the person(s) performing the work to ensure that the product still complies with the requirements of the above standards.

Spare parts and wear parts can be ordered through your nearest ESAB dealer, see

esab.com. When ordering, please state product type, serial number, designation and spare

part number in accordance with the spare parts list. This facilitates dispatch and ensures correct delivery.

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ORDERING NUMBERS

Ordering no. Denomination Product Notes

0398 146 016 Welding tractor Railtrac™ B42V

0398 146 801 Orbital kit Railtrac™ B42V

0463 467 001 Spare parts list Railtrac™ B42V

Technical documentation is available on the Internet at: www.esab.com

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ACCESSORIES

1. 0457 360 880 Control cable (12p- 23p) Railtrac™ - MEK

2. 0457 360 886 Universal connection cable 12-pin plug

3. 0457 467 880 Transformer 230/36 VAC with 12-pin plug

0457 467 882 Transformer 115VAC

The work piece tractor is mounted on the rail. The light flexible aluminium rail can be used on objects that are flat, curved or round and can be fitted to the surface in different ways. It is supplied in standard 2.5 metre lengths and can be extended to any required length. The rail can be mounted permanently on the work object or temporarily fixed with magnets or vacuum fixtures. It may also be attached to the outside or inside of a tube. A stiffener bar may be used to stiffen the flexible rail.Rails for tubes can be purchased at ESAB distributors.

0398 146 115 Flexible alu rail 2.5 metres

0398 146 119 Flexible alu rail 5 metres

0398 146 112 Flexible alu rail 2.5 metres with 8 magnets

(FlipMag)

0398 146 113 Flexible alu rail 2.5 metres with vacuum

attachments

0398 146 116 Stiffener bar 2.5 metres

0398 146 100 Flip magnetic attachment at least 8 pcs per

2.5 metres

0398 146 104 Vacuum attachment 90°, at least 4 pcs per

2.5 metres

0398 146 105 Vacuum attachment 200°, at least 4 pcs per

2.5 metres

0398 146 114 Screw attachment for stiffened rail at least

8 pcs per 2.5 metres

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ACCESSORIES

0398 145 211 Floating welding head

A floating welding head holds the torch of the welding or cutting equipment at a constant height above the surface during the work.

To enable correct weaving motions even in troublesome positions the weaving unit can be fitted with supports for turning and tilting.

0398 145 106 Torch holder universal Ø15-30 mm

System features different torch holders for different torches and applications. Railtrac™ B42V comes with a universal torch holder (Ø10-22 mm) and adjusters as standard.

0398 145 101 Torch holder for ESAB PSF torches

0398 146 801 Orbital kit

With the optional Orbital kit the B42V can be used for orbital welding of pipes from 20" and up, in horizontal and vertical joints, with or without weaving.

0398 145 202 Tilt bracket Railtrac™ B42V

The tilt bracket enables the Railtrac™ to weave when welding fillet joints. It is mounted between drive and weaving unit. The weaving unit can be tilted from 0 to 60 degrees.

0398 145 203 Turning bracket B42

The turning bracket is used to change the angle of the weaving unit at ±22 degrees from travel direction.

0398 145 211 Floating head

This component helps maintain constant stick-out at the welding torch or cutting torch.

0457 467 880 Transformer 230 VAC

0457 467 882 Transformer 115 VAC

0457 360 880 Connection cable ESAB, 12 + 23-pin

Release in November 2016

0457 360 886 Connection cable universal, for start/stop

wire feeder, only with 12-pin

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ACCESSORIES

0398 146 120 Quick-extension bracket for flexible rail

The quick-extension bracket facilitates rapid mounting and dismounting when using two rails.

0449 900 720 Orbital ring 20”

0449 900 722 Orbital ring 22”

0449 900 724 Orbital ring 24”

0449 900 726 Orbital ring 26”

0449 900 728 Orbital ring 28”

0449 900 730 Orbital ring 30”

0449 900 732 Orbital ring 32”

0449 900 734 Orbital ring 34”

0449 900 736 Orbital ring 36”

0449 900 738 Orbital ring 38”

0449 900 740 Orbital ring 40”

0449 900 742 Orbital ring 42”

0449 900 744 Orbital ring 44”

0449 900 746 Orbital ring 46”

0449 900 748 Orbital ring 48”

0449 900 750 Orbital ring 50”

0449 900 752 Orbital ring 52”

0449 900 754 Orbital ring 54”

0449 900 756 Orbital ring 56”

0449 900 758 Orbital ring 58”

0449 900 760 Orbital ring 60”

0449 900 762 Orbital ring 62”

0457 468 074 Battery 18 V / 5 Ah Makita®

0457 468 072 Battery charger 230 VAC Makita®

For local purchase at hardware store Makita®

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ACCESSORIES

196673-6 BL1850

18 V

18 V 5.0 Ah Li-ion.

195585-0 DC18RC

14,4 V - 18 V

Charger for 14,4 V-18 V batteries.

Cable key function diagram

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ACCESSORIES

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ESAB AB, Lindholmsallén 9, Box 8004, 402 77 Gothenburg, Sweden, Phone +46 (0) 31 50 90 00

http://manuals.esab.com

For contact information visit esab.com

ESAB Railtrac B42V Instruction manual

Specifications and Main Features

Frequently Asked Questions

User Manual

TABLE OF CONTENTS

1 SAFETY

1.1 Meaning of symbols

1.2 Safety precautions

2 INTRODUCTION

3 TECHNICAL DATA

4 INSTALLATION

4.1 Connections

4.2 Assembly

4.3 Assembly instructions for the optional Orbital kit

5 OPERATION

5.1 Preheat

5.2 Remote control for digital wire feeder

5.3 Electronic – Carriage

5.4 Remote control

5.5 Installation of wire feeder

6 MAINTENANCE

7 ORDERING SPARE PARTS

ORDERING NUMBERS

ACCESSORIES